Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Gibson, Brian T.; Mhatre, Paritosh; Borish, Michael C.; Atkins, Celeste E.; Potter, John T.; Vaughan, Joshua E.; Love, Lonnie J.

doi:10.1016/j.addma.2022.103048

Title: Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Journal Article · 20 July 2022 · Additive Manufacturing

DOI: https://doi.org/10.1016/j.addma.2022.103048 · OSTI ID:1883911

^[1]; Mhatre, Paritosh ^[1];

^[1];

^[1]; Potter, John T. ^[2];

^[1];

^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); GKN Aerospace, Hazelwood, MO (United States)

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1883911

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: 1 Vol. 58; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (46)

A tool vector control for laser additive manufacturing in five-axis configuration Tang, Qingchun; Yin, Shaohui; Zhang, Yi The International Journal of Advanced Manufacturing Technology, Vol. 98, Issue 5-8 https://doi.org/10.1007/s00170-018-2177-5	journal	June 2018
An approach to partition workpiece CAD model towards 5-axis support-free 3D printing Liu, Hao; Liu, Lei; Li, Dawei The International Journal of Advanced Manufacturing Technology, Vol. 106, Issue 1-2 https://doi.org/10.1007/s00170-019-04495-3	journal	November 2019
FIBR3DEmul—an open-access simulation solution for 3D printing processes of FDM machines with 3+ actuated axes Faria, Carlos; Fonseca, Jaime; Bicho, Estela The International Journal of Advanced Manufacturing Technology, Vol. 106, Issue 7-8 https://doi.org/10.1007/s00170-019-04713-y	journal	January 2020
Adaptive process control implementation of wire arc additive manufacturing for thin-walled components with overhang features Lam, Teng Foong; Xiong, Yi; Dharmawan, Audelia Gumarus The International Journal of Advanced Manufacturing Technology, Vol. 108, Issue 4 https://doi.org/10.1007/s00170-019-04737-4	journal	December 2019
An experimental investigation of the effectiveness of Ar-CO2 shielding gas mixture for the wire arc additive process Silwal, Bishal; Nycz, Andrzej; Masuo, Christopher J. The International Journal of Advanced Manufacturing Technology, Vol. 108, Issue 5-6 https://doi.org/10.1007/s00170-020-05395-7	journal	May 2020
Radial slicing for helical-shaped advanced manufacturing applications Munasinghe, Nuwan; Paul, Gavin The International Journal of Advanced Manufacturing Technology, Vol. 112, Issue 3-4 https://doi.org/10.1007/s00170-020-05999-z	journal	December 2020
Defect Identification and Mitigation Via Visual Inspection in Large-Scale Additive Manufacturing Borish, Michael; Post, Brian K.; Roschli, Alex JOM, Vol. 71, Issue 3 https://doi.org/10.1007/s11837-018-3220-6	journal	November 2018
Slicing algorithms for multi-axis 3-D metal printing of overhangs Lee, Kyubok; Jee, Haeseong Journal of Mechanical Science and Technology, Vol. 29, Issue 12 https://doi.org/10.1007/s12206-015-1113-y	journal	December 2015
Helical slicing method for material extrusion-based robotic additive manufacturing Yigit, Ismail Enes; Lazoglu, I. Progress in Additive Manufacturing, Vol. 4, Issue 3 https://doi.org/10.1007/s40964-019-00090-w	journal	June 2019
Directed light fabrication of a solid metal hemisphere using 5-axis powder deposition Milewski, J. O.; Lewis, G. K.; Thoma, D. J. Journal of Materials Processing Technology, Vol. 75, Issue 1-3 https://doi.org/10.1016/S0924-0136(97)00321-X	journal	March 1998
Process planning for additive manufacturing of geometries with variable overhang angles using a robotic laser directed energy deposition system Kaji, Farzaneh; Jinoop, Arackal Narayanan; Zimny, Mark Additive Manufacturing Letters, Vol. 2 https://doi.org/10.1016/j.addlet.2022.100035	journal	April 2022
CAM planning for multi-axis laser additive manufacturing considering collisions Plakhotnik, Denys; Glasmacher, Lothar; Vaneker, Tom CIRP Annals, Vol. 68, Issue 1 https://doi.org/10.1016/j.cirp.2019.04.007	journal	January 2019
Investigation of novel trochoidal toolpath strategies for productive and efficient directed energy deposition processes Soshi, Masakazu; Odum, Kyle; Li, Geng CIRP Annals, Vol. 68, Issue 1 https://doi.org/10.1016/j.cirp.2019.04.112	journal	January 2019
Wire-arc additive manufacturing of structures with overhang: Experimental results depositing material onto fixed substrate Evjemo, Linn Danielsen; Langelandsvik, Geir; Moe, Signe CIRP Journal of Manufacturing Science and Technology, Vol. 38 https://doi.org/10.1016/j.cirpj.2022.04.006	journal	August 2022
Fabrication of metallic parts with overhanging structures using the robotic wire arc additive manufacturing Yuan, Lei; Pan, Zengxi; Ding, Donghong Journal of Manufacturing Processes, Vol. 63 https://doi.org/10.1016/j.jmapro.2020.03.018	journal	March 2021
In-process path replanning and online layer height control through deposition arc current for gas metal arc based additive manufacturing Ščetinec, Aljaž; Klobčar, Damjan; Bračun, Drago Journal of Manufacturing Processes, Vol. 64 https://doi.org/10.1016/j.jmapro.2021.02.038	journal	April 2021
Improved wear resistance of directed energy deposited Fe-Ni-Cr alloy via closed-loop controlling laser power Su, Youyu; Wang, Zhanfeng; Lu, Haifei Journal of Manufacturing Processes, Vol. 75 https://doi.org/10.1016/j.jmapro.2022.01.047	journal	March 2022
A review on wire arc additive manufacturing: Monitoring, control and a framework of automated system Xia, Chunyang; Pan, Zengxi; Polden, Joseph Journal of Manufacturing Systems, Vol. 57 https://doi.org/10.1016/j.jmsy.2020.08.008	journal	October 2020
Iterative hybrid manufacture of a titanium alloy component Honeycutt, Andrew; Mhatre, Paritosh; Gibson, Brian Manufacturing Letters, Vol. 29 https://doi.org/10.1016/j.mfglet.2021.07.003	journal	August 2021
Interplay between powder catchment efficiency and layer height in self-stabilized laser metal deposition Donadello, Simone; Furlan, Valentina; Demir, Ali Gökhan Optics and Lasers in Engineering, Vol. 149 https://doi.org/10.1016/j.optlaseng.2021.106817	journal	February 2022
Reduction of Support Structures and Building Time by Optimized Path Planning Algorithms in Multi-axis Additive Manufacturing Coupek, Daniel; Friedrich, Jens; Battran, David Procedia CIRP, Vol. 67 https://doi.org/10.1016/j.procir.2017.12.203	journal	January 2018
Geometry-Based Process Planning for Multi-Axis Support-Free Additive Manufacturing Murtezaoglu, Yavuz; Plakhotnik, Denys; Stautner, Marc Procedia CIRP, Vol. 78 https://doi.org/10.1016/j.procir.2018.08.175	journal	January 2018
Automatic multi-direction slicing algorithms for wire based additive manufacturing Ding, Donghong; Pan, Zengxi; Cuiuri, Dominic Robotics and Computer-Integrated Manufacturing, Vol. 37 https://doi.org/10.1016/j.rcim.2015.09.002	journal	February 2016
Process planning for 8-axis robotized laser-based direct metal deposition system: A case on building revolved part Ding, Yaoyu; Dwivedi, Rajeev; Kovacevic, Radovan Robotics and Computer-Integrated Manufacturing, Vol. 44 https://doi.org/10.1016/j.rcim.2016.08.008	journal	April 2017
Research and implementation of a non-supporting 3D printing method based on 5-axis dynamic slice algorithm Wang, Mingqian; Zhang, Haiguang; Hu, Qingxi Robotics and Computer-Integrated Manufacturing, Vol. 57 https://doi.org/10.1016/j.rcim.2019.01.007	journal	June 2019
Robot assisted additive manufacturing: A review Urhal, Pinar; Weightman, Andrew; Diver, Carl Robotics and Computer-Integrated Manufacturing, Vol. 59 https://doi.org/10.1016/j.rcim.2019.05.005	journal	October 2019
Layer-by-layer generation of optimized joint trajectory for multi-axis robotized additive manufacturing of parts of revolution Chalvin, Maxime; Campocasso, Sébastien; Hugel, Vincent Robotics and Computer-Integrated Manufacturing, Vol. 65 https://doi.org/10.1016/j.rcim.2020.101960	journal	October 2020
Inclined slicing and weld-deposition for additive manufacturing of metallic objects with large overhangs using higher order kinematics Panchagnula, Jayaprakash Sharma; Simhambhatla, Suryakumar Virtual and Physical Prototyping, Vol. 11, Issue 2 https://doi.org/10.1080/17452759.2016.1163766	journal	April 2016
Oxidation of Ti-6Al-4V During Wire and Arc Additive Manufacture Caballero, Armando; Ding, Jialuo; Bandari, Yashwanth 3D Printing and Additive Manufacturing, Vol. 6, Issue 2 https://doi.org/10.1089/3dp.2017.0144	journal	April 2019
Fabrication of curved overhanging thin-walled structure with robotic wire and arc additive manufacturing (RWAAM) Li, Yifeng; Qin, Xunpeng; Wu, Qiang Industrial Robot: the international journal of robotics research and application, Vol. 47, Issue 1 https://doi.org/10.1108/IR-05-2019-0112	journal	August 2019
Curved layer path planning on a 5-axis 3D printer Duarte, Joao; Espírito Santo, Isabel; T. Monteiro, M. Teresa Rapid Prototyping Journal, Vol. 28, Issue 4 https://doi.org/10.1108/RPJ-02-2021-0025	journal	October 2021
End lateral extension path strategy for intersection in wire and arc additive manufactured 2319 aluminum alloy Li, Runsheng; Zhang, Haiou; Dai, Fusheng Rapid Prototyping Journal, Vol. 26, Issue 2 https://doi.org/10.1108/RPJ-05-2019-0123	journal	October 2019
A review of slicing methods for directed energy deposition based additive manufacturing Xu, Jing; Gu, Xizhi; Ding, Donghong Rapid Prototyping Journal, Vol. 24, Issue 6 https://doi.org/10.1108/RPJ-10-2017-0196	journal	October 2018
Curved-layered material extrusion modeling for thin-walled parts by a 5-axis machine Feng, Xiaojing; Cui, Bin; Liu, Yaxiong Rapid Prototyping Journal, Vol. 27, Issue 7 https://doi.org/10.1108/RPJ-11-2020-0272	journal	July 2021
Research on the Control System and Digital Model of new 5-Axis 3D Printer Based on Stewart Parallel Mechanism Ma, Baocong; Meng, Chao; Tian, Xiangke 2021 IEEE 5th Advanced Information Technology, Electronic and Automation Control Conference (IAEAC) https://doi.org/10.1109/IAEAC50856.2021.9390595	conference	March 2021
Process planning for robotic wire and arc additive manufacturing Ding, Donghong; Pan, Zengxi; Cuiuri, Dominic 2015 IEEE 10th Conference on Industrial Electronics and Applications (ICIEA) https://doi.org/10.1109/ICIEA.2015.7334441	conference	June 2015
Heat Input Control in 3D Laser Cladding Based on Infrared Sensing Hu, Dongming; Wu, Yunxin; Kovacevic, Radovan Manufacturing Engineering https://doi.org/10.1115/IMECE2001/MED-23337	conference	November 2001
Thermal imaging for assessment of electron-beam freeform fabrication (EBF ³ ) additive manufacturing deposits Zalameda, Joseph N.; Burke, Eric R.; Hafley, Robert A. SPIE Defense, Security, and Sensing, SPIE Proceedings https://doi.org/10.1117/12.2018233	conference	May 2013
Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University Nassar, Abdalla R.; Reutzel, Edward W.; Brown, Stephen W. SPIE LASE, SPIE Proceedings https://doi.org/10.1117/12.2217855	conference	April 2016
A survey of thermal sensing application in additive manufacturing Borish, Michael Thermosense: Thermal Infrared Applications XLIII https://doi.org/10.1117/12.2587059	conference	April 2021
Modelling and measuring the thermal behaviour of the molten pool in closed-loop controlled laser-based additive manufacturing Hu, D.; Kovacevic, R. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 217, Issue 4 https://doi.org/10.1243/095440503321628125	journal	April 2003
Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study Mbodj, Natago Guilé; Abuabiah, Mohammad; Plapper, Peter Applied Sciences, Vol. 11, Issue 24 https://doi.org/10.3390/app112411949	journal	December 2021
Effect of Interlayer Cooling Time, Constraint and Tool Path Strategy on Deformation of Large Components Made by Laser Metal Deposition with Wire Lee, Yousub; Bandari, Yashwanth; Nandwana, Peeyush Applied Sciences, Vol. 9, Issue 23 https://doi.org/10.3390/app9235115	journal	November 2019
Model-Based Feedforward Control of Part Height in Directed Energy Deposition Wang, Qian; Li, Jianyi; Nassar, Abdalla R. Materials, Vol. 14, Issue 2 https://doi.org/10.3390/ma14020337	journal	January 2021
Strength Increasing Additive Manufacturing Fused Filament Fabrication Technology, Based on Spiral Toolpath Material Deposition Avdeev, Artem; Shvets, Andrey; Gushchin, Ilya Machines, Vol. 7, Issue 3 https://doi.org/10.3390/machines7030057	journal	September 2019
Testbed for Multilayer Conformal Additive Manufacturing Kutzer, Michael; DeVries, Levi Technologies, Vol. 5, Issue 2 https://doi.org/10.3390/technologies5020025	journal	May 2017

Similar Records

Slicing Solutions for Wire Arc Additive Manufacturing

Journal Article · 2025 · Journal of Manufacturing and Materials Processing · OSTI ID:2543133

Sebok, Michael; Lai, Canhai; Masuo, Chris; +8 more

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

Conference · 2020 · OSTI ID:2205461

Gibson, Brian; Mhatre, Paritosh; Borish, Michael; +10 more

Metamodels for Rapid Analysis of Large Sets of Building Designs for Robotic Constructability: Technology Demonstration Using the NASA 3D Printed Mars Habitat Challenge

Conference · 2023 · OSTI ID:1957996

Muthumanickam, Naveen Kumar; Duarte, Jose Pinto; Nazarian, Shadi; +1 more

Related Subjects

36 MATERIALS SCIENCE
5-Axis
Directed energy deposition
Laser
Robotics
Slicing
Titanium

Title: Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Citation Formats

References (46)

Similar Records

Related Subjects